Insect barrier fabric

ABSTRACT

An insect barrier fabric includes a fabric substrate, a plurality of conical spacers formed within the fabric substrate, where each conical spacer being defined by a cone shaped depression having an open top end within the fabric substrate and a converging bottom end. In addition, a coating is formed over a surface of each of the conical spacers. The plurality of conical spacers are configured to suspend the fabric substrate away from a skin of a user in order to protect against insect bites.

FIELD

The present invention relates to the field of fabrics, and, more particularly, to an insect barrier fabric and related methods.

BACKGROUND

Insects are more than just an annoyance at picnics. According to the CDC, over 3.2 billion people are at risk from mosquito borne malaria with 200 million cases at any one time resulting in over 500,000 deaths per year. In Africa, children under the age of five constitute 77% of the deaths. Mosquitoes have been found to transmit four types of encephalitis, West Nile virus, Dengue Fever, Rift Valley Fever and 200,000 annual infections of Yellow Fever, of which 30,000 prove fatal. The Chikungunya Virus, spread by a mosquito that bites both day and night, now affects twenty-four Caribbean islands and is headed for Florida. Tick borne Lyme Disease presents in a constellation of symptoms ranging from mild to debilitating. Black flies are a vector for the parasitic nematode causing onchocerciasis, or river blindness. Sleeping sickness is transmitted by the Tetsi Fly. Lieschmoniasis, spread by sand flies, infects more than 1.5 million people annually.

Many attempts have been made and tried to protect against the scourge of various insects. This includes the use of a variety of sequestration such as pesticides, repellant chemicals, screens, shrouds and protective clothing, the latter effective but impractical in a tropical climate.

For example, a beekeeper's suit and other variations may incorporate an inside and an outside membrane encapsulating an inner cellular layer of material to form a protective barrier. However, the suit traps heat and is uncomfortable to wear for extended periods of time. Other attempts include an ultra-fine synthetic netting worn over clothing. Still yet other attempts include combining layers of fabric to provide spacing coupled with repellants and/or insecticides. However, there remains a need for an inexpensive, air permeable, easily manufactured, effective means of keeping insects from biting people while allowing them to remain cool.

SUMMARY

The present invention relates to the field of fabrics, and, more particularly, to an insect barrier fabric and related methods. The insect barrier fabric includes a fabric substrate, a plurality of conical spacers formed within the fabric substrate, where each conical spacer defined by a cone shaped depression having an open top end within the fabric substrate and a converging bottom end. In addition, a coating is formed over a surface of each of the conical spacers. The fabric substrate may be a mesh material and the plurality of conical spacers configured to suspend the fabric substrate away from a respective surface such as the skin of a person. The coating over the conical spacers may be a flexible sealant and the plurality of conical spacers may be arranged in a diamond pattern. In a particular embodiment, the insect barrier fabric may be a shirt that can be worn and the fabric substrate may be a woven material. The plurality of conical spacers may be formed from the fabric substrate.

In another particular embodiment, a method of manufacturing an insect barrier fabric includes providing a fabric substrate, forming a plurality of conical spacers within the fabric substrate, where each conical spacer is defined by a cone shaped depression having an open top end within the fabric substrate and a converging bottom end. The method also includes forming a coating over a surface of each of the conical spacers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a particular embodiment of an insect barrier fabric;

FIG. 2 is a top partial view of the insect barrier fabric of FIG. 1;

FIG. 3 is a partial cross sectional view taken along the line 3-3 of FIG. 2;

FIG. 4 is a partial perspective view of insect barrier fabric;

FIG. 5 is a perspective detail view of a conical spacer of the insect barrier fabric; and

FIG. 6 is a cross sectional view of the conical spacer in the direction of line 6-6 of FIG. 5.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.

The present insect barrier fabric is a significant improvement over exiting mosquito netting. For example, the insect barrier fabric may be used for insect preventive clothing, bedcovers and sleeping bags and addresses an inherent flaw in existing mosquito netting. More particularly, the present invention relates to a new configuration of insect barrier fabric whereby it is manufactured, or modified, into a shape that frustrates the attempts of insects to penetrate. For example, the insect barrier fabric may be formed into a shirt worn by a person, where the insect barrier fabric creates a space between the surface of the insect barrier fabric and the skin of the person. The space created is greater than that which can be penetrated by a proboscis of a mosquito but while allowing ventilation.

The insect barrier fabric may be manufactured by reconstructing a generally planar two dimensional sheet of mesh fabric into a precisely conformed semi-rigid three dimensional structure. The insect barrier fabric may be self-supported by integrated spacing elements so that the efficacy is increased by an order of magnitude.

The insect barrier fabric may be used for clothing, garments, blankets, sleeping bags, bed shrouds or any other use of mosquito type netting that protects the wearer from being stung by mosquitoes or other insects while allowing the wearer to remain cool. A garment or bed shroud made from insect barrier fabric may be draped over the skin of the wearer and be effective in helping to prevent insect bites or stings while sleeping.

Referring now to FIG. 1, the insect barrier fabric 100 increases the ability of the wearer 102 to avoid the stings and bites of insects while remaining cool and well ventilated. In this particular embodiment, the insect barrier fabric 100 has been made into a shirt having arm sleeves 104 and a neck opening 106. The insect barrier fabric 100 includes a plurality of conical spacers 108.

Referring now to FIG. 2, the insect barrier fabric 100 may include a fabric substrate 110 having the plurality of conical spacers 108 formed within the fabric substrate 110 itself, where each conical spacer 108 is defined by a cone shaped depression in the fabric substrate 110 having an open top end within the fabric substrate 110 and a converging bottom end that is closed. A coating is formed over a surface of each of the conical spacers 108 in order to prevent an insect from crawling into the conical spacers 108 and reaching the skin of the wearer. The coating is impermeable to the insects. The fabric substrate 110 may be a mesh material similar to that used currently as mosquito netting.

As illustrated in FIG. 3, the plurality of conical spacers 108 are configured to suspend the fabric substrate 110 away from a respective surface such as the skin 112 of the wearer 102. The open top end 114 of the conical spacer 108 narrows to a converging bottom end 116 and a tip 118 that is the only portion of the conical spacer 108 that touches the skin 112 of the wearer 102.

Referring now to FIG. 4, the plurality of conical spacers 108 are arranged in rows and columns to form a diamond pattern within the fabric substrate 110. The spacing between the conical spacers 108 may depend on the rigidity of the fabric substrate 110, but generally a spacing of about 20 mm to 40 mm, for example, and arranged in a diamond pattern is sufficient to maintain the distance of the fabric substrate 110 above the skin 112 to protect against insect bites.

The insect barrier fabric 100 may include a woven or non-woven mesh substrate 110, and incorporating on its surface the regularly interspaced pattern of molded funnel or conical spacers 108. The conical spacers 108 may be formed from the fabric substrate 110 itself, for the purpose of elevating the insect barrier fabric 100 sufficiently above the skin 112 of the wearer 102 to establish a space through which insects cannot sting or bite, or about 9.6 mm in a particular embodiment. The interior of the conical spacer 108 is impervious to penetration by insects. As explained above, the insect barrier fabric 100 is suitable for the production of, or incorporation into, garments, bed covers, and sleeping bags.

Accordingly, the insect barrier fabric 100 may be manufactured using a unique molding of mosquito netting material, of natural or synthetic composition, into a configuration that creates a space between the skin 112 of the wearer and attacking insects. Incorporated on and extending beneath the fabric substrate 110 of the insect barrier fabric 100 is a repeating pattern of the conical spacers 108. In general, mosquitoes and insects can easily penetrate existing mosquito netting. The space created between the fabric substrate 110 and the skin 112 of the wearer 102 may be used to separate the barrier surface of the insect barrier fabric 100 from the skin.

Using the malleability of the fabric substrate 110, the fabric substrate 110 can be distorted to produce the conical spacer 108. The tip 118 of the conical spacer 108 can rest on the skin 112 of the wearer 102 and the height of its vertical axis will determine the surface height of the fabric substrate 110 thus suspended. The lateral distance between the conical spacers, shown in FIG. 4, may be selected based on the rigidity of the substrate 110, but generally a spacing of 20 mm to 40 mm arranged in a diamond pattern is sufficient to keep the surface of the substrate 110 a constant height of approximately 9.6 mm, in a particular embodiment. The insect barrier fabric 100 is suitable for clothing, bed covering, sleeping bags or any other application that would benefit from the improvement.

Referring now to FIGS. 5 and 6, in the event an aggressive insect or mosquito attempts to crawl into the conical spacer 108 through the open top end 114, the descending sides and terminal end 122 of the conical spacer 108 are coated with a flexible coating 120 that incorporates and encapsulates the fibers of the fabric substrate 110 and becomes an essential element in retaining the shape, resilience and rebound memory of the conical spacer 108. Tests have shown that mosquitoes are not particularly flexible, require a stable stance when biting and are deterred from venturing into an interior of the conical spacer 108. In addition, tests have shown a conical (shape) spacer 108 is a strong configuration easily assumed by a variety of fabrics, and lends itself to high speed molding processes and, when compressed, recedes into the surrounding fabric.

The insect barrier fabric 100 may be manufactured in a single, high speed mill run using molds and available injection techniques as would be appreciated to those skilled in the art. Therefore, the insect barrier fabric 100 may be manufactured inexpensively and weighs only a fraction more than the constituent fabric due in part to the conical spacer 108 coating. Since the garments utilizing or incorporating the insect barrier fabric 100 can lay directly on exposed skin 112, garments can be form-fitting and far less bulky than currently available bug jackets. This feature allows for shirts and pants that have fashionable design elements such collars, buttons, zippers and pockets to be comprised of the insect barrier fabric 100.

The method of manufacturing the insect barrier fabric 100 may include providing the fabric substrate 110, forming the plurality of conical spacers 108 within the fabric substrate 110, where each conical spacer 108 being defined by a cone shaped depression having an open top end 114 within the fabric substrate 110 and a converging bottom end 116, and forming the coating 120 over a surface of each of the conical spacers 108. The conical spacers 108 provide for the insect barrier fabric 100 to be “stuffed” into packages for sale or convenient storage by users.

In a particular embodiment as a bed shroud, the insect barrier fabric 100 protects a sleeper should he or she inadvertently come into contact with the surface of the insect barrier fabric 100 being draped over the bed. Relieved of this hazard, a smaller amount of insect barrier fabric 100 would be needed.

Due to its relatively minimalist nature, the insect barrier fabric 100 affords increased air permeability and ventilation, therefore increased cooling. Since the tips 118 of the conical spacers 108 make contact with the skin 112 rather than the field of the fabric substrate 110, the insect barrier fabric 100 virtually floats over the skin 112 of the user 102 and conducts an insignificant amount of thermal energy to the body of the user 102. Nor does the insect barrier fabric 100 trap significant heat dissipating from a body.

In a particular embodiment, the coating 120 may have reflective properties so that on the upward facing surface (away from the skin 112) of the insect barrier fabric 100, there is a reduction in infrared and ultraviolet energy transmission to the underlying skin 112.

Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. 

That which is claimed is:
 1. An insect barrier fabric comprising: a fabric substrate; a plurality of conical spacers formed within the fabric substrate, wherein each conical spacer defined by a cone shaped depression having an open top end within the fabric substrate and a converging bottom end; and a coating formed over a surface of each of the conical spacers.
 2. The insect barrier fabric of claim 1, wherein the fabric substrate is a mesh material.
 3. The insect barrier fabric of claim 1, the plurality of conical spacers configured to suspend the fabric substrate away from a respective surface.
 4. The insect barrier fabric of claim 3, wherein the respective surface is a skin of a person.
 5. The insect barrier fabric of claim 1, wherein the coating is a flexible sealant.
 6. The insect barrier fabric of claim 1, wherein the plurality of conical spacers are arranged in a diamond pattern.
 7. The insect barrier of claim 1, wherein the fabric substrate comprises a shirt.
 8. The insect barrier of claim 1, wherein the fabric substrate is a woven material.
 9. The insect barrier of claim 1, wherein the plurality of conical spacers are formed from the fabric substrate.
 10. An insect barrier fabric comprising: a fabric mesh substrate; a plurality of conical spacers formed within the fabric substrate, wherein each conical spacer defined by a cone shaped depression having on open top end within the fabric substrate and a converging bottom end; and a flexible coating formed over a surface of each of the conical spacers; wherein the plurality of conical spacers being configured to suspend the fabric substrate away from a respective surface.
 11. The insect barrier fabric of claim 10, wherein a depth of the cone shaped depression from the open top end to the converging bottom end is about 9.5 millimeters.
 12. The insect barrier fabric of claim 10, wherein the flexible coating comprises a reflective material configured to reflect visible and infrared light waves.
 13. The insect barrier fabric of claim 10, wherein the insect barrier fabric comprises a shirt.
 14. A method of manufacturing an insect barrier fabric comprising: providing a fabric substrate; forming a plurality of conical spacers within the fabric substrate, wherein each conical spacer defined by a cone shaped depression having an open top end within the fabric substrate and a converging bottom end; and forming a coating over a surface of each of the conical spacers.
 15. The method of claim 14, wherein the fabric substrate is a mesh material.
 16. The method of claim 14, wherein the plurality of conical spacers configured to suspend the fabric substrate away from a respective surface.
 17. The method of claim 16, wherein the respective surface is a skin of a person.
 18. The method of claim 14, wherein the coating is a flexible sealant.
 19. The method of claim 14, wherein the plurality of conical spacers are arranged in a diamond pattern.
 20. The method of claim 14, wherein the coating comprises a reflective material. 